Engine:
Detailed disassembly, assembly, repair, troubleshooting for all engine variants (Boxer Twin Cam, Boxer Diesel).
Fuel System:
Carburetor and fuel injection systems (Bosch L-Jetronic, K-Jetronic, Motronic), fuel pump, lines, injectors, fuel tank.
Ignition System:
Distributor, coils, spark plugs, electronic ignition control, timing adjustments.
Cooling System:
Radiator, thermostat, water pump, hoses, fan, coolant specifications.
Exhaust System:
Exhaust manifolds, catalytic converter (where applicable), mufflers, pipes, emission control systems.
Transmission:
Manual transmission (5-speed transaxle) repair, clutch, gearbox overhaul, lubricant specifications.
Drivetrain:
Front-wheel drive system, driveshafts, CV joints, differential.
Suspension:
Front McPherson struts, rear independent suspension, bushings, springs, shock absorbers, alignment specifications.
Steering:
Steering rack, tie rods, power steering system (where equipped), steering column.
Brakes:
Front discs, rear discs/drums (depending on model/year), hydraulic system, master cylinder, calipers, brake lines, parking brake.
Electrical System:
12V system, battery, alternator, starter motor, fuse box, wiring diagrams, lighting, wipers, horn.
Body And Chassis:
Body panel removal/installation, doors, windows, locks, interior trim, chassis repair, rust prevention.
HVAC:
Heating, ventilation, and air conditioning system diagnosis and repair (where applicable).
Body Electrical:
Power windows, central locking, instruments, warning lights.
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt adjustments.
Troubleshooting:
Diagnostic charts, common problems and solutions for all major systems.
Engine Repair:
Engine rebuilds, head gasket replacement, piston ring replacement, valve adjustments.
Transmission Repair:
Clutch replacement, gearbox disassembly and reassembly, synchromesh repair.
Brake System Repair:
Brake pad/shoe replacement, caliper/wheel cylinder overhaul, brake fluid bleeding, parking brake adjustment.
Suspension And Steering Repair:
Replacement of ball joints, tie rod ends, control arm bushings, shock absorbers, steering rack overhaul.
Electrical Diagnostics:
Use of multimeters, troubleshooting wiring faults, starter/alternator testing.
Bodywork Repair:
Panel alignment, rust repair techniques, glass replacement, door mechanism repair.
Tune Up Procedures:
Ignition timing, carburetor adjustment, fuel injection system checks.
Torque Specifications:
Crucial torque values for all critical fasteners.
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostics.
Oil Change Interval:
Typically every 10,000-15,000 km or 12 months, whichever comes first (refer to manual for exact spec).
Timing Belt Interval:
Critical for Boxer engines. Typically 60,000 - 80,000 km or 4-5 years. Failure can cause severe engine damage.
Engine Oil:
API SG/SH rated, SAE 10W-40 or 15W-50 (check manual for specific grade based on temperature).
Coolant:
Ethylene glycol based antifreeze/coolant mixture (50/50). Capacity approx. 6.5-7.5 liters.
Transmission Fluid:
API GL-4 SAE 75W-90 or 80W-90 gear oil. Capacity approx. 2.0 - 2.5 liters.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Rust Tendency:
Significant rust issues, particularly on sills, wheel arches, and floor pans, due to Alfasud heritage and Italian manufacturing practices of the era.
Electrical Gremlins:
Aging wiring harnesses, corrosion in connectors, and early electronic component failures can lead to intermittent electrical issues.
Carburetor Issues:
Carburetors (especially Weber DCNF/DCNS) can become maladjusted, leading to rough idling, poor fuel economy, or starting problems.
Suspension Wear:
Wear in control arm bushings, ball joints, and tie rod ends is common due to age and mileage, affecting handling and steering precision.
Engine Oil Leaks:
Boxer engines can be prone to oil leaks from the crankcase joints, oil cooler, and valve covers due to aging seals and gaskets.